LB4000 + RLB2000 Integrated Asphalt Mixing Plant

Technical Specification (Full English Translation)**

Part 1 — General Specifications

1. General Parameters of LB4000 Asphalt Mixing Plant

Production capacity: 280–360 t/h (rated conditions, continuous feeding)

Fuel consumption: ≤ 6.5 kg/t (rated conditions)

Rated working conditions include:

1. Aggregate moisture content: 3 percent

2. Finished material temperature: 140°C

3. Ambient temperature: 20°C

4. Site elevation: below 1000 m

5. Fuel type: heavy oil or natural gas, heating value 9800 kcal/kg

6. Aggregate gradation entering the mixer must be correct and meet specification requirements

Measurement accuracy:

Aggregate: ±0.5 percent

Mineral powder: ±0.5 percent

Asphalt: ±0.25 percent

Dust removal performance after baghouse filtration:

Dust emission: < 50 mg/Nm3

Ringelmann blackness: < Grade 1

Environmental noise: < 70 dB(A), measured 20 m from the maximum noise source

Other parameters:

Total installed power: 1100 kW

Total equipment weight: approx. 500 t

Required site area: length 58 m, width 52 m

Component Specifications

2. Aggregate Feeding System (Primary Cold Feeding)

Cold aggregate bins: six units

Each bin capacity: 10 m3

Feeding port size: 3.6 m × 2.45 m

Loading height: 4.32 m

Note: Each bin is equipped with a grizzly screen to prevent oversized material from entering.

Belt feeders: six units

Belt size: 650 mm × 2.79 m

Production capacity:

Sand: 100 t/h

Aggregate: 100 t/h (aggregate size < 40 mm)

Variable‑frequency motor:

Motor power: 2.2 kW

Adjustment ratio: 20:1

Accuracy: ±2 percent

Bin wall vibrators: two units installed on sand bins

Motor power: 750 W

Collecting belt conveyor: one unit

Motor power: 7.5 kW

Belt width: 700 mm

Capacity: 480 t/h

Inclined belt feeder: one unit

Motor power: 7.5 kW

Belt width: 700 mm

Capacity: 480 t/h

3. RAP Cold Feeding System

RAP bins: two units

Each bin capacity: 15.5 m3

Feeding port: 3.6 m × 2.45 m

Loading height: 4.32 m

With protective grizzly screen

RAP belt feeders: two units

Belt size: 650 mm × 2.79 m

Variable‑frequency motor: 2.2 kW

Adjustment ratio: 20:1

Accuracy: ±2 percent

Bin wall vibrators: two units

Motor power: 750 W

4. Environmental Protection System (Cold Feeding Area)

Baghouse dust collector: 100 filter bags

Induced draft fan power: 15 kW

Axial fans and ducting: included

Drying Drum System

Drying drum dimensions:

Diameter: 2.9 m

Length: 11 m

Shell thickness: 18 mm

Drive method: four friction‑drive rollers

Drive motors: 4 × 30 kW

Insulation: 50 mm high‑temperature insulation felt, stainless steel outer cladding

Production capacity: 480 t/h

Temperature control:

Sensor type: thermal resistance

Measurement error: < ±5°C

5. Main Burner (FRD‑JZ4000)

Maximum output power: 26.5 MW

Maximum fuel consumption: 2250 kg/h

Turn‑down ratio: 1:4

Main fuel: diesel, heavy oil, fuel oil

Ignition fuel: acetylene

Flame length: approx. 5.6 m

Flame diameter: approx. 1.3 m

Flame temperature: approx. 1300°C

Combustion efficiency: > 99 percent

Electrical power consumption: ≤ 38 kW

Compressed air consumption: ≤ 5.5 m3/min

Silencing method: reflective muffler

Air compressor:

Air delivery: 6 m3/min

Pressure: 0.85 MPa

Motor power: 37 kW

RAP Drying Drum System

RAP drum diameter: 2200 mm

RAP drum length: 10 m

Inclination: 3 degrees

Drive motor power: 4 × 15 kW

Temperature rise: 120–140°C

Maximum aggregate size: 40 mm

Rated RAP drying capacity:

1 percent moisture: 160 t/h

3 percent moisture: 100 t/h

The drum uses four‑wheel friction drive. The support frame is welded from H‑beam steel and bolted to the platform to form the drum inclination. Four sets of support rollers with roller bearings support the drum. Two sets of thrust rollers at the inlet end prevent axial movement.

Inside the drum, materials first pass through guide blades in the flame zone to prevent material curtains. After the flame zone, special lifting blades form a uniform curtain for efficient heat exchange.

RAP Burner (FRD‑TR/H1500)

Maximum output power: 10 MW

Maximum fuel consumption: 850 kg/h

Maximum gas consumption: 980 m3/h

Turn‑down ratio: 1:4

Main fuel: natural gas, heavy oil, fuel oil

Main valve size: DN100

Ignition fuel: acetylene

Flame length: approx. 3.5 m

Flame diameter: approx. 0.8 m

Flame temperature: 1300–1800°C

Combustion efficiency: > 99 percent

Motor power consumption: 22 kW

Compressed air consumption: 3 m3/min

The burner control system supports remote automatic ignition, monitoring, automatic shutdown on fault, fault diagnosis, and safety protection.

RAP temporary storage bin: 9 m3

RAP weighing hopper: 2 m3

Weighing method: three‑point load cell

Discharge gate: pneumatic

Environmental sealing: color steel enclosure

1. Hot Aggregate Elevator

Type: vertical, fully enclosed, double‑row ring chain, equipped with anti‑reverse braking motor

Lifting capacity: 480 t/h

Drive motor power: 37 kW (gear reducer)

RAP Elevator

Type: vertical, fully enclosed, double‑row ring chain

Lifting capacity: 240 t/h

2. Vibrating Screen

Type: high‑speed inclined vibrating screen, six‑deck configuration

Screening capacity: 480 t/h

Number of aggregate fractions: six

Drive motor power: 2 × 11 kW

3. Insulated Hot Aggregate Bins

Type: six‑compartment insulated storage bins with 50 mm insulation

Total storage capacity: 100 t

Level detection: inductive level sensors

Temperature detection: temperature sensor installed in sand bin

Additional features: overflow pipe

Control system: electro‑pneumatic discharge system with coarse and fine weighing for each aggregate size

4. Aggregate Weighing Hopper

Type: single‑hopper, four‑point load‑cell weighing

Weighing capacity: 5500 kg

Load cells: four units, equipped with transport locking bolts

Maintenance access: dust‑proof chamber with service manhole

Control: electro‑pneumatic discharge system

Discharge chute dimensions: 4500 × 1500 × 600 mm

5. Asphalt Weighing Hopper

Type: single‑hopper, insulated, heated by thermal oil, three‑point load‑cell weighing

Capacity: 480 kg

Load cells: three units with transport locking bolts

Asphalt feeding method: gravity flow into mixer

Control: electro‑pneumatic discharge system

Additional feature: automatic asphalt over‑fill protection

6. Mineral Powder Weighing Hopper

Type: single‑hopper, sealed, three‑point load‑cell weighing

Capacity: 600 kg

Load cells: three units with transport locking bolts

Control: electro‑pneumatic discharge system

7. Weighing System Characteristics

All weighing hoppers are mounted on independent load‑cell groups.

Weight signals are transmitted to the control room via shielded cables.

Processed signals support both manual and automatic operation modes.

Digital display and automatic compensation for “in‑flight” material are included.

8. Insulated Mixer

Type: twin‑shaft paddle mixer with thermal‑oil‑heated mixing chamber

Rated mixing capacity: 5000 kg per batch

Drive method: dual‑motor synchronous drive for both shafts

Drive motor power: 2 × 75 kW (gear reducers)

Mixer Performance

Mixing cycle time: 45 seconds

Mixing capacity: 400 t/h

9. Mixing Tower Structure

The mixing tower assembly includes built‑in lifting equipment for maintenance.

Truck passage under the tower: width 6.9 m, height 3.9 m

Asphalt Supply System

1. Asphalt Storage Tanks

Configuration:

Two standard asphalt tanks

Two mixing asphalt tanks

All tanks heated indirectly by thermal oil with automatic temperature control

Tank quantity and capacity: 4 × 50,000 L

Heating method: thermal‑oil coil heat exchanger

Insulation: thermal insulation with corrugated steel outer cladding

Level detection: continuous level indicators

Mixing system: two tanks equipped with dual agitators

2. Asphalt Unloading Pit

Capacity: 1 m3

Pump type: thermal‑oil‑heated screw pump

Motor power: 7.5 kW

Pump insulation: thermal‑oil heating

3. Asphalt Transfer Pump

Type: thermal‑oil‑heated screw pump

Flow rate: 35 m3/min

Motor power: 15 kW

Pump insulation: thermal‑oil heating

4. Thermal Oil Heater

Model: RL130L.C

Burner: fully automatic ignition and monitoring, diesel‑fired, automatic temperature control and protection

Heating capacity: 1,000,000 kcal/h

Maximum oil temperature: ≤ 260°C

Thermal oil circulation pump:

High‑temperature centrifugal type

Flow rate: 30 m3/h

Pressure: 1.6 MPa

Motor power: 7.5 kW

Control system:

Programmable computer control

Automatic monitoring of temperature, circulation, oil level, and pressure

Automatic alarms and burner start/stop control

Thermal oil: supplied by user (recommendations available upon request)

5. Heavy Oil Tank

Capacity: 50 m3

Mineral Powder Supply System

1. New Powder Silo

Capacity: 60 m3

Feeding method: pneumatic feeding from bulk powder truck

Over‑pressure protection: automatic relief valve on silo top

Level detection: inductive level sensors

Anti‑arching system: compressed‑air arch‑breaking device

2. Recovered Powder Silo

Capacity: 80 m3

Feeding method: elevator feeding

Level detection: inductive level sensors

Anti‑arching system: compressed‑air floating device

Excess powder handling: elevator return and humidified discharge

3. Screw Conveyors

Three units with the following specifications:

273 mm × 4000 mm, 7.5 kW

273 mm × 3500 mm, 5.5 kW

323 mm × 4000 mm, 11 kW

1. Dust Collection System Overview

Type: primary gravity settling chamber plus secondary baghouse dust collector

Primary dust removal performance: separation of particles ≥ 75 μm

Secondary dust removal performance: dust emission ≤ 50 mg/Nm3

(When raw aggregates are washed and screened, emissions can reach 15 mg/Nm3)

Maximum air handling capacity: 147,000 m3/h at 115°C

Normal operating temperature: 100–150°C

2. Primary Dust Collector

Type: gravity‑type dust separator

Features:

Installed at the inlet of the secondary dust collector

Equipped with wear‑resistant plates and adjustable guide vanes

Guide vanes allow adjustment of settling particle size (normally ≥ 75 μm)

Collected dust is returned to the hot elevator via screw conveyors

Screw Conveyors (Primary Dust Return)

Two units

Dimensions:

273 mm × 4000 mm, 7.5 kW

273 mm × 3500 mm, 5.5 kW

3. Baghouse Dust Collector

Type: atmospheric reverse‑pulse cleaning system

Filter bag material: NOMEX, 500 g/m2, silicon‑treated for easy cleaning

Number of filter bags: 1350

Total filtration area: 1490 m2

Bag replacement: top‑extraction type

Cleaning method: electromagnetic pulse jet, group‑timed, adjustable

Temperature monitoring: thermocouple with display, control, and over‑temperature protection

Adjustable airflow restrictor: multi‑blade type, remotely controlled from control room

Pressure differential monitoring: differential pressure gauge with remote display

Structure: rain‑proof insulated enclosure with corrugated steel cladding

Maintenance access: cage ladder, platforms, guardrails

4. Induced Draft Fan

Type: centrifugal

Motor power: 220 kW

Air volume: 147,000 m3/h at 115°C

5. Dust Recovery System

Dust return method: pneumatic conveying

Dust is lifted into the reclaimed powder silo

Elevator motor power: 11 kW

6. Waste Powder Humidifier

One unit

Motor power: 15 kW

Used for humidified discharge of excess dust

Finished Material Storage Silo

1. Storage Silo Configuration

Main silo type: bottom‑mounted storage silo

Main silo capacity: 120 t

Waste/overflow silo capacity: 10 t

2. Receiving Corridor

A fully enclosed receiving corridor is installed under the silo discharge area

Front and rear equipped with fast rolling doors

Remote‑controlled opening and closing

Purpose: prevent asphalt fumes and dust from escaping during truck loading

3. Fume Treatment System

Equipped with a photo‑ion oxidation processor for asphalt fume decomposition

Motor power: 22 kW

Includes axial fans and ducting for fume extraction

Control System

1. Control System Overview

Type: large‑screen LCD computer control system

One display for operation, one display for management

Control modes: manual, semi‑automatic, and fully automatic

Power supply: 380 V / 220 V (±5 percent), 50 Hz, three‑phase four‑wire

2. Motor Control

Protection: circuit breaker, short‑circuit protection, overload protection, contactor

Operation: push‑button operation with automatic protection

3. Weighing Control System

Computer‑based weighing control

Color display

Automatic weighing

Automatic in‑flight compensation

Asphalt over‑weigh protection

Recipe input and printout functions

4. Mixing Control

Computer automatic program control

Manual or fully automatic operation

Recipe temperature input supported

5. Burner Control

Computer automatic program control

Automatic start and ignition

Safety monitoring

Automatic shutdown on fault

Fault diagnosis and protection

Painting

Standard plant color: gray

Dust collection system color: silver‑white

Other colors available upon request at time of order

User‑Supplied Items

1. Transformer and cables from transformer to control room

2. Lubricating oil, grease, and thermal oil

3. Foundation materials: sand, stone, cement

4. Power system: single‑circuit three‑phase four‑wire unless otherwise specified

5. Lightning protection system

1. Cold Aggregate Feeding System

Cold aggregate bins: six units, 10 m³ each, manufactured by Shandong Zhenhua

Feeder motor and reducer: 2.2 kW, six units, Guomao brand

Vibration motors: 750 W, two units, domestic premium brand

Frequency inverters: six units, Delta Taiwan

Belts: 650 mm endless type, six units, Qingdao

Flat belt conveyor: > 480 t/h, one unit, Shandong Zhenhua

Flat belt motor and reducer: 7.5 kW, one unit, Guomao

Inclined belt conveyor: > 480 t/h, one unit, Shandong Zhenhua

Inclined belt motor and reducer: 7.5 kW, one unit, Guomao

Grizzly screens: 60 × 80 mm, six units, Shandong Zhenhua

2. Drying Drum System

Drying drum: 2.9 m × 11 m, one unit, Shandong Zhenhua

Drive motor and reducer: 30 kW, four units, Guomao

Support roller bearings: model 22324CC/C3W33, eight units, TMK USA

Thrust roller bearings: model 6326 GB/T 276, two units, TMK USA

Thermocouple temperature sensor: Pt100, one unit, Shanghai

3. Burner System (Heavy Oil)

Heavy‑oil burner: model 4000, one unit, Degibona

Heavy‑oil tank: 50 m³, one unit, Shandong Luhong

Insulation material: aluminum silicate insulation, Shandong Luhong

4. Mixing Tower Assembly

Hot aggregate elevator: > 480 t/h, one unit, Shandong Zhenhua

Elevator motor and reducer: 37 kW, one unit, Guomao

Sprockets: quenched 45# steel, two units, Shandong Zhenhua

Ring chain: double‑ring chain, Shandong Zhenhua

Vibrating screen motors: MVE17500/1 (11 kW), two units, OLI‑Wolong Italy

Screen meshes: six‑layer configuration, eleven sets, Beijing Hongxing

Hot aggregate bins: six compartments with large and small discharge gates, one unit, Shandong Zhenhua

Bin cylinders: twelve units, Xinyi Shanghai

Bin level sensors: six units, Liaoyang

Mixer reducers: 75 kW, two units, Guomao

Load cells: pressure type, ten units, Ruima

Mixer discharge cylinder: one unit, Xinyi Shanghai

Finished material silo: 120 t, bottom‑mounted, one unit, Shandong Zhenhua

Silo cylinders: two units, Xinyi Shanghai

5. Dust Collection System

Induced draft fan: 220 kW, one unit, Jinan Chuangke

Baghouse dust collector: pulse‑jet type, 1490 m² filtration area, one unit, Hebei Huanke

Internal dust screw conveyor: one unit, Hebei Huanke

Screw conveyors: 5.5 kW, two units, Shandong Zhenhua

Waste powder humidifier: one unit, Shandong Zhenhua

Humidifier motor and reducer: 15 kW, one unit, Shandong Zhenhua

Cylinder: one unit, Xinyi Shanghai

Thermocouple: Pt100, one unit, Shanghai

6. Powder Storage System

New powder silo: 60 m³, one unit, Shandong Zhenhua

Level sensor: one unit, Liaoyang

Butterfly valve: DN300, one unit, Shanghai

Silo top dust collector: one unit, Hebei

Screw conveyor: 11 kW, one unit, Shandong Zhenhua

Reclaimed powder silo: 88 m³, one unit, Shandong Zhenhua

Waste powder elevator: one unit, Shandong Zhenhua

Elevator motor and reducer: 11 kW, one unit, Guomao

Ring chain: double‑ring chain, Shandong Zhenhua

Screw conveyors: 7.5 kW, two units, Shandong Zhenhua

7. Pneumatic System

Screw‑type air compressor: 6 m³/min, 37 kW, two units, Kaishan Zhejiang

Air storage tank: 1 m³, two units, Kaishan Zhejiang

8. Central Control System

Control room: one unit, Shandong Zhenhua

Main electrical components: Schneider France

Computer: Lenovo business desktop

Monitor: 21‑inch Lenovo

Printer: HP

Air conditioner: 3‑ton cabinet type, AUX

Cables: supplied by Liaocheng Yanggu

9. Asphalt Storage and Heating Unit

Asphalt storage tanks: 4 × 50 m³, Shandong Luhong

Thermal oil heater: 1,000,000 kcal/h, Hebei

Insulation material: aluminum silicate, Hebei

Burner: 1,000,000 kcal/h, Riello

Asphalt pump: three‑screw pump, 15 kW

Insulated three‑way valve: DN80, five units, Shandong Luhong

High‑temperature shut‑off valve: DN50, eight units, Shandong Luhong

Asphalt unloading pit pump: three‑screw pump, 7.5 kW, Shandong Luhong

10. Environmental Protection System

Cold feeding dust collection: baghouse with 100 filter bags, 15 kW fan, axial fans, Hebei Huanke

Main tower fume extraction: sealed discharge corridor, spray tower, plasma photo‑ion unit, axial fans, 22 kW induced fan, Hebei Huanke

11. RAP System Components

RAP cold bins: 2 × 10 m³, Shandong Zhenhua

Feeder motor and reducer: 2.2 kW, two units, Guomao

Vibration motors: 750 W, two units

Frequency inverters: two units, Delta Taiwan

Belts: 650 mm, two units, Qingdao

Flat belt conveyor: 700 mm, one unit, Shandong Zhenhua

Flat belt motor and reducer: 7.5 kW, one unit, Guomao

Inclined belt conveyor: 700 mm, one unit, Shandong Zhenhua

12. RAP Elevator

Capacity: 120–160 t/h, one unit, Shandong Zhenhua

Elevator motor and reducer: 5.5 kW, one unit, Guomao

Sprockets: quenched 45# steel, two units

Ring chain: double‑ring chain, Shandong Zhenhua

13. RAP Drying Drum

Drum size: 2.2 m × 10 m, one unit, Shandong Zhenhua

Drive motor and reducer: 15 kW, four units, Guomao

Support roller bearings: 22319CA, eight units, TMK USA

Thrust roller bearings: 7214AC, four units, TMK USA

Burner: model 1500, one unit, Degibona

14. RAP Weighing System

RAP temporary storage bin: 9 m³, Shandong Zhenhua

RAP weighing hopper: 2 m³, Shandong Zhenhua

Load cells: pressure type, three units, Ruima

Discharge cylinders: four units, Xinyi Shanghai

Special Tools Supplied with Equipment

The following tools are supplied with the asphalt mixing plant:

Double‑ended box wrench set, eight pieces

Double‑ended open wrench set, eight pieces

Adjustable wrench 36 × 300 mm

Adjustable wrench 55 × 450 mm

Combination pliers 200 mm

Pipe wrench 45 × 350 mm

Flat file 250‑II

Flat‑head screwdriver 200 × 8 mm

Phillips screwdriver 200 × 8 mm

Electrician’s screwdriver 100 × 5 mm

Machinist hammer 0.5 kg

Octagonal hammer 8.2 kg

High‑pressure grease gun

Oil can, 1 kg capacity

Note: Actual supplied tools may vary due to technical improvements.

1. Main Tower Fume Extraction System

A complete fume extraction and purification system is installed around the mixer discharge area.

Its purpose is to capture asphalt fumes and dust generated during material discharge and truck loading.

1.1 Extraction Ducting and Axial Fans

Extraction ducts and multiple axial fans are installed around the discharge gates.

These components continuously draw asphalt fumes and dust from the discharge zone.

1.2 Enclosed Truck Loading Corridor

A fully enclosed corridor approximately 15 meters long is installed beneath the discharge area.

The corridor includes:

• Front and rear high‑speed rolling doors

• Remote‑controlled opening and closing

• Sealed structure to prevent fume leakage

• Structural frame made of 100 × 100 mm and 60 × 40 mm square tubing

• Exterior cladding made of 1 mm corrugated steel sheets

Purpose:

To ensure asphalt fumes and dust remain contained during truck loading.

2. Fume Collection System for the Finished Material Silo

A dedicated extraction system is installed at the silo discharge point.

2.1 Ring‑Shaped Extraction Duct

A ring‑shaped duct with a cross‑section of 300 × 500 mm and a length of approximately 15 meters is installed around the discharge area.

Constructed from 3 mm steel plate.

2.2 Connection Ducts

Two connection ducts, each 4.5 meters long, connect the ring duct to the main extraction line.

2.3 Axial Fans

Eighteen axial fans, each rated at 0.37 kW, provide distributed suction along the duct.

2.4 Front and Rear Extraction Ducts

Two ducts, each 3.5 meters long, cross‑section 300 × 500 mm, constructed from 3 mm steel plate.

Purpose:

To ensure uniform suction and prevent fume accumulation.

3. Photo‑Ion Plasma Purification System

This is the core environmental protection device for asphalt fume treatment.

3.1 System Components

The system includes:

• Primary connection duct (300 × 500 mm, 1.5 m long)

• Secondary connection duct (800 mm diameter, 6.8 m long)

• Water spray tower

• Three quick‑connect couplings (800 mm diameter, 0.5 m long)

• Four 90‑degree elbows (800 mm diameter)

• Straight duct (800 mm diameter, 3.8 m long)

• Photo‑ion purification unit

• Induced draft fan (22 kW)

• Chimney connection duct (430 × 500 mm, 1.2 m long)

• Chimney (800 mm diameter, 7.5 m long)

3.2 Operating Principle

1. Fumes are extracted from the discharge area.

2. Fumes pass through the spray tower for cooling and particulate removal.

3. Fumes enter the photo‑ion plasma reactor, where high‑energy ions break down asphalt fume molecules.

4. Purified air is discharged through the chimney.

3.3 Performance

• High decomposition efficiency for asphalt fumes

• Low maintenance requirements

• Stable long‑term operation

• Suitable for continuous high‑temperature environments

4. Cold Feeding Dust Collection System

This system handles dust generated at the cold aggregate feeding area.

4.1 Sealed Cold Feeding Structure

The cold bins and inclined belt conveyor are fully sealed using:

• 100 × 100 mm and 60 × 40 mm steel tubing

• Corrugated steel sheets (1 mm thick)

Purpose:

To prevent dust escape during loader feeding.

4.2 Dedicated Baghouse Dust Collector

A separate baghouse with approximately 100 filter bags is installed for the cold feeding area.

It captures dust generated during aggregate loading and belt transfer.

4.3 Automatic Dust Extraction Control

Each cold bin is equipped with an automatic butterfly valve.

When the system detects loader feeding, the corresponding valve opens and dust is extracted into the baghouse.

4.4 Ducting and Components

The system includes:

• Axial fans (0.37 kW), sixteen units

• Multiple extraction ducts (500–600 mm diameter)

• Pneumatic flap valves

• Pneumatic cylinders (QSC80 × 200)

• Baghouse dust collector

• Induced draft fan

• Chimney and connection ducts

Purpose:

To ensure dust is captured at the source and does not escape into the environment.

5. Installation and Commissioning

The manufacturer provides:

• Free installation

• Free commissioning

• On‑site adjustment of all environmental protection systems

• Training for operators